Beckett 7600 User manual

Beckett
Brand
Beckett
Model
7600
Category
Water heaters & boilers
Type
User manual

This manual is also suitable for

PARTS & ACCESSORIES
Description / Applications
The Beckett AquaSmart™ is an advanced boiler control designed for use on
residential and light commercial boiler systems. All models include the option of
enabling Beckett HeatManager™ dynamic temperature reset that, when selected,
provides up to 20% fuel consumption savings. The control includes a backlit LCD
digital display with touch pad to easily program temperature limits, differentials,
and other advanced options. The AquaSmart™ also has memory storage of
system history for help with diagnostics and troubleshooting.
2
HeatManager™ dynamic temperature reset for
additional energy savings
—
DOE 2012 Compliant
—
Meets NR CAN proposed 2012 requirements
Advanced microprocessor-based design
Backlit LCD digital display with installer
programming touch pad
Quick access to system cycle history
Onboard power disconnect switch (optional)
High/Low limit and High/Low differential
adjustments
24Vac Thermostat compatible
Circulator control - 120Vac
Zone Control - 120Vac (programmable priority
override for domestic hot water)
Temperature sensor mounts in standard
immersion wells
Compatible retrofi t for most standard boiler
temperature controls
Programmable circulator-on and -off delays
Helps prevent freeze-up by energizing circulator
and ZC if an error condition is detected.
Periodically exercises circulator pump to help
prevent sieze-up.
Cold-start compatible
6-pin vent damper receptacle on 7500B for easy
wiring to most vent dampers.
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Features
Table of Contents
Features........................................................................ 2
Technical Specifi cations ............................................. 3
Electrical Ratings ..........................................................................3
Temperature Ranges and Differentials ..........................................3
Environmental Ratings ..................................................................3
Approvals ......................................................................................3
Installation .................................................................... 4
Mounting .......................................................................................4
AquaSmart Models and Cross-Reference Guide ..........................5
Removing the Control to be Replaced ..........................................7
Installing the Temperature Sensor ................................................7
Installing the 2-in-1 Sensor ...........................................................8
2-in-1 Sensor Technical Specifi cations .........................................8
2-in-1 Installation Instructions .......................................................9
Test the Low Water Cut-off (LWCO) Safety Function ....................9
Installing the AquaSmart Control
.....................................................10
Immersion Well or 2-in-1 Sensor ................................................ 10
Appliance Surface ...................................................................... 10
Wiring ........................................................................ 10
Wiring the AquaSmart Control .....................................................11
Programming Basic Functions ................................ 25
A. Temperature High Limit .......................................................... 25
B. Temperature Low Limit........................................................... 25
C. Temperature High Limit Differential ....................................... 25
D. Temperature Low Limit Differential ........................................ 26
Programming Additional Options ............................ 26
A. Changing the Heat Manager Settings .................................... 26
B. Viewing the Boiler Cycle History ............................................ 26
C. Changing the Circulator Settings ........................................... 27
D. Changing Domestic Hot Water Priority (DHWP) Setting ....... 28
E. Selecting Fahrenheit or Celsius Temperature Display ........... 28
F. Changing Low Water Cut-Off (LWCO) Setting ....................... 28
AquaSmart Operation ............................................... 30
Control Checkout Procedure ...................................................... 30
How a Boiler Control Works ....................................................... 31
Display Boiler Status Mode ........................................................ 32
Troubleshooting ........................................................ 32
Lockout ....................................................................................... 32
HeatManager Technology ......................................... 32
Final Checklist ........................................................... 33
Accessories ............................................................... 33
Service ........................................................................ 33
Mounting Template .................................................... 35
Limited Warranty Information .................................. 36
Electrical Shock, Fire,
Explosion and Burn Hazards
This control must be installed, adjusted and put
into operation only by a trained, licensed, qualifi ed
professional or service agency in accordance with
the National Electric Code ANSI/NFPA 70 (Canada
CSA C22.1) state, local codes and authorities having
jurisdiction.
The installer must carefully read and follow the
installation and service instructions contained in this
manual and make them available to the equipment
owner, so they can be kept for future reference.
This product is not suitable for temperature control of
pools, spas, or Jacuzzis.
This product is not to be used as a step or a shelf.
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3
AquaSmart Boiler Control Manual
Figure 1 - Getting to know the AquaSmart 7600 Series Control
Temperature Ranges and Differentials
High Limit Setting Range: 100 to 240°F (37 to 115°C)
High Limit Differential Range: 5 to 45°F (2 to 25°C)
Low Limit Setting Range: 100 to 220°F (37 to 104°C)
Low Limit Differential Range: 10 to 45°F (5 to 25°C)
Factory Range Stops available - consult factory
Environmental Ratings
Storage Temperature: -40 to +150°F (-40 to +65°C)
Operating Temperature: -4 to +150°F (-20 to +65°C)
7600B at 50 Hz: -4 to +140°F (-20 to +60°C)
Maximum Sensing Element Temperature: 250°F (121°C)
Relative Humidity: 5 to 85% RH, non-condensing and
non-crystallizing
Approvals
Underwriters Laboratories Listed to UL353,
UL1998 for U.S. and Canada;
CSA C22.2 No. 24
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Technical Specifi cations
Electrical Ratings
Input Voltage: 120 Vac - 50/60 Hz.
Input Current: 0.1 A + B1 + C1 + ZC
MAX Input Current: 20A (Reduce to 15A if optional
power disconnect switch is used)
24 Vac Thermostat Anticipator Current: 0.1 Amp.
Burner Current Rating (B1):
7600A (oil): 7.4 A at 120 Vac FLA; 44.4 A inrush LRA.
7600B (gas): 1.25 A at 24 Vac; 30 VA (total load).
Circulator Current Rating (C1): 7.4 A at 120 Vac FLA;
44.4 A inrush LRA.
Zone Control Current Rating (ZC): 7.4 A at 120 Vac
FLA; 44.4 A inrush LRA.
Do Not Use This Control in
an Application that is Not
Within the Ratings Listed in This Section.
Improper Control Operation May Result.
Electrical Shock Hazard
The AquaSmart control should only be operated with the door attached and securely closed.
Rotate door until grooves
are aligned
Pull door up
TW/TR Terminals
Communication Port
Sensor Jack
Touch Pad
Power Disconnect Switch (Optional)
Clamping Screw For Sensor
Sensor Mount
Door Removal
4
Figure 2 - Basic Dimensions (inches)
Mounting
OEM Installation: When replacing an OEM-installed
AquaSmart, consult the appliance manufacturer’s wiring
diagrams and instructions for additional information.
Retrofi t Installation: The AquaSmart can be used to
replace most standard boiler temperature controls. For a
cross-reference of compatible replacements, refer to
Table 1.
There are two basic methods for mounting the
AquaSmart to the boiler as outlined in Figure 3.
Sensor/Immersion Well Mounting – This is the
most common method. If the existing well is not
suitable for any reason, a standard design
aftermarket immersion well with the proper
dimensions can be purchased from a HVAC
distributor. The AquaSmart can then be mounted in
the typical way.
Surface Mounting – This is sometimes required
and is part of the AquaSmart base design. The
base has adequate clearance built-in to
accommodate the temperature sensor lead exiting
the back of the control.
A remote mounting kit (Pt.
No. 7600RMU) that includes a 48” extension cable
and mounting screws can be purchased separately
for applications where needed.
1.
2.
Installation
Figure 3 - Mounting Options
Surface Mounting:
Sensor/Immersion Well Mounting:
Position the strain relief over the hex,
capturing the sensor cable and crimp to secure.
4.92
4.50
3.51
3.04
5.38
.75
3.50
SK10013
6.50
Sensor Lead
(a 48”
extension cable can be
purchased separately)
5
AquaSmart Boiler Control Manual
AquaSmart Models and Cross-Reference Guide
Table 1a - Direct Replacements
Honeywell
Beckett
Replacement
Notes
L7148F (All)
L8148E (All)
7600B
Must confi rm that 7600 VA rating is adequate to meet VA requirements of system.
Make sure 7600 B1 output does not exceed 1.25A @ 24VAC (30 VA).
7600 outputs are not rated for 240 VAC.
B2, TW and TR terminals replace TV, T and Z, respectively.
L8124A (All)
L8124C (All)
7600A
7600 outputs are not rated for 240 VAC.
L7124A/C (All)
L7148A (All)
L7224
A/C/U
(All)
L7248A/C (All)
7600A
The 7600 has no Honeywell EnviraCOM
TM
Communications port.
The diagnostic LED lights are replaced by the 7600’s display.
L8148A (All) 7600A
7600 outputs are not rated for 240 VAC.
B1 terminal on 7600 utilizes a 1/4” quick connect.
Set low limit on 7600 to OFF.
L8124E 1016
L8148E 1265
7600B
7600 outputs are not rated for 240 VAC.
B2, TW and TR terminals replace TV, T and Z, respectively.
L8124M (All) 7600A
For replacement with the 7600: Turn low limit off so the circulator is controlled directly by the thermostat and ZC is constantly powered.
L8151A 7600A
7600 outputs are not rated for 240 VAC.
Remote mount sensor cable needed (Part No. 52120)
Hydrolevel
Beckett
Replacement
Notes
3100 7600B
Not a suitable replacement if Low Water Cutoff (LWCO) functionality of the 3100 is used.
3150 7600A
Not a suitable replacement if Low Water Cutoff (LWCO) functionality of the 3150 is used.
Carlin
Beckett
Replacement
Notes
90524A 7600A
Make sure 7600 outputs do not exceed 7.4A.
Available operating limit and differential ranges are not equivalent. Compare the settings to the AquaSmart ranges before replacing.
The diagnostic LED lights are replaced by the 7600’s display.
White Rodgers
Beckett
Replacement
Notes
11C15-11 7600A
Make sure 7600 outputs do not exceed 7.4A @ 120 VAC. 7600 outputs are not rated for 240 VAC.
8B48A-217 7600A
11C30-3
11B54-4
7600A
Make sure 7600 outputs do not exceed 7.4A @ 120 VAC. 7600 outputs are not rated for 240 VAC.
Available operating limit and differential ranges are not equivalent. Compare the settings to the AquaSmart ranges before replacing.
8F48A-351
8B43A-601
7600B
11C61-12 7600A
Not a suitable replacement if SPDT switch action is required; only break-on-rise available on 7600.
Make sure 7600 outputs do not exceed 7.4A @ 120 VAC. 7600 outputs are not rated for 240 VAC.
Table 1b - Functional Replacement (Advanced Wiring Needed)
Honeywell
Beckett
Replacement
Notes
L4006A (All)
L4006G 1022
L4006H 1004
L4008A (All)
L4080B/D
7600A or 7600B
(Based on System
Voltage
Requirements)
Make sure 7600 outputs do not exceed 7.4A @ 120 VAC. 7600 outputs are not rated for 240 VAC.
7600 will require an additional wire (L2) for operation. Short TW-TR terminals. C1, C2, ZC, and ZR are unused.
Set low limit on 7600 to OFF.
Available operating limit and/or differential ranges may not be equivalent. Compare the settings to the AquaSmart ranges before replacing.
To use with a millivolt system, an appropriate voltage relay with isolated gold plated contacts must be added to switch the millivolt circuit.
L4006E (All)
L4008E (All)
L4080F/G
7600A or 7600B
(Based on System
Voltage
Requirements)
Requires the addition of a manual-reset high limit.
Make sure 7600 outputs do not exceed 7.4A @ 120 VAC. 7600 outputs are not rated for 240 VAC.
7600 will require an additional wire (L2) for operation. Short TW-TR terminals. C1, C2, ZC, and ZR are unused.
Set low limit on 7600 to OFF.
Available operating limit and/or differential ranges may not be equivalent. Compare the settings to the AquaSmart ranges before replacing.
To use with a millivolt system, an appropriate voltage relay with isolated gold plated contacts must be added to switch the millivolt circuit.
(Table continued on next page)
Burn, Scald, Explosion, and Equipment Malfunction Hazard
Replacement of the following controls must be done only by a qualifi ed service agency or technician who is
trained and experienced in the use of boiler controls.
Carefully follow these guidelines and the directions provided by the manufacturer of the control being replaced.
Note: Beckett assumes no liability for incorrect installation or replacement.
6
Honeywell
Beckett
Replacement
Notes
L4081A/B
L6081A/C
7600A or 7600B
(Based on System
Voltage
Requirements)
Remove switching relay, if used, from the system when replacing the L4081 or L6081.
Make sure 7600 outputs do not exceed 7.4A @ 120 VAC. 7600 outputs are not rated for 240 VAC.
L6006A (All)
L6006C 1018
L6008A 1192
L6008A 1242
7600A or 7600B
(Based on System
Voltage
Requirements)
Not a suitable replacement if SPDT switch action is required; only break-on-rise available on 7600.
To use with a millivolt system an appropriate voltage relay with isolated gold plated contacts must be added to switch the millivolt circuit.
Make sure 7600 outputs do not exceed 7.4A @ 120 VAC. 7600 outputs are not rated for 240 VAC.
7600 will require an additional wire (L2) for operation. Short TW-TR terminals. C1, C2, ZC, and ZR are unused.
Set low limit on 7600 to OFF.
Available operating limit and/or differential ranges may not be equivalent. Compare the settings to the AquaSmart ranges before replacing.
L8124B 1039
L8148J 1009
7600A or 7600B
(Based on System
Voltage
Requirements)
To use with a millivolt system an appropriate voltage relay with isolated gold plated contacts must be added to switch the millivolt circuit.
7600 outputs are not rated for 240 VAC.
Carlin
Beckett
Replacement
Notes
90200A
7600A or 7600B
(Based on System
Voltage
Requirements)
Make sure 7600 outputs do not exceed 7.4A.
Set low limit on 7600 to OFF.
Available operating limit and differential ranges are not equivalent. Compare the settings to the AquaSmart ranges before replacing.
90000 (All)
90200E
90200EL
90300B
7600A or 7600B
(Based on System
Voltage
Requirements)
Requires the addition of a manual-reset high limit.
Make sure 7600 outputs do not exceed 7.4A.
Set low limit on 7600 to OFF.
Available operating limit and differential ranges are not equivalent. Compare the settings to the AquaSmart ranges before replacing.
90200D
7600A or 7600B
(Based on System
Voltage
Requirements)
Not a suitable replacement if SPDT switch action is required; only break-on-rise available on 7600.
Make sure 7600 outputs do not exceed 7.4A.
Set low limit on 7600 to OFF.
Available operating limit and differential ranges are not equivalent. Compare the settings to the AquaSmart ranges before replacing.
White
Rodgers
Beckett
Replacement
Notes
11B06-1
11D18-1
11B18-101
11B30-104
11B02-1
1145-33
7600A or 7600B
(Based on System
Voltage
Requirements)
Make sure 7600 outputs do not exceed 7.4A @ 120 VAC. 7600 outputs are not rated for 240 VAC.
7600 will require an additional wire (L2) for operation. Short TW-TR terminals. C1, C2, ZC, and ZR are unused.
Set low limit on 7600 to OFF.
11B06-46
11B95-31
11B18-153
7600A or 7600B
(Based on System
Voltage
Requirements)
Make sure 7600 outputs do not exceed 7.4A @ 120 VAC. 7600 outputs are not rated for 240 VAC.
7600 will require an additional wire (L2) for operation. Short T
W-TR terminals. C1, C2, ZC, and ZR are unused.
Set low limit on 7600 to OFF.
Available operating limit and/or differential ranges are not equivalent. Compare the settings to the AquaSmart ranges before replacing.
11D82-1
11D31-1
1131-102
1127-2
11A79-2
7600A or 7600B
(Based on System
Voltage
Requirements)
Not a suitable replacement if SPDT switch action is required; only break-on-rise available on 7600.
7600 outputs are not rated for 240 VAC.
7600 will require an additional wire (L2) for operation. Short TW-TR terminals. C1, C2, ZC, and ZR are unused.
Set low limit on 7600 to OFF.
1127-9
7600A or 7600B
(Based on System
Voltage
Requirements)
Not a suitable replacement if SPDT switch action is required; only break-on-rise available on 7600.
7600 outputs are not rated for 240 VAC.
7600 will require an additional wire (L2) for operation. Short TW-TR terminals. C1, C2, ZC, and ZR are unused.
Set low limit on 7600 to OFF.
Available operating limit and/or differential ranges may not be equivalent. Compare the settings to the AquaSmart ranges before
replacing.
11B27-9
7600A or 7600B
(Based on System
Voltage
Requirements)
Requires the addition of a manual-reset high limit.
Make sure 7600 outputs do not exceed 7.4A @ 120 VAC. 7600 outputs are not rated for 240 VAC.
7600 will require an additional wire (L2) for operation. Short T
W-TR terminals. C1, C2, ZC, and ZR are unused.
Set low limit on 7600 to OFF.
Available operating limit and/or differential ranges are not equivalent. Compare the settings to the AquaSmart ranges before replacing.
8J48A-209
7600A or 7600B
(Based on System
Voltage
Requirements)
To use with a millivolt system an appropriate voltage relay with isolated gold plated contacts must be added to switch the millivolt circuit.
Table 1b (continued from previous page)
7
AquaSmart Boiler Control Manual
Compare the attached wires to available wiring
diagrams on the control cover and to the devices to
which they can be traced. If wiring diagrams have
been lost they are available later in this manual.
Label each wire accordingly, to ensure accurate
reconnection. (Masking tape works well for labeling.)
Remove each wire from the old control. Make sure
each label is intact.
Loosen the control mounting arrangement and remove
the control from the system.
Make note of the temperature settings for high limit,
low limit and differentials. This will provide important
reference data for the new control adjustment. Please
note that differentials may be used differently in other
manufacturer’s controls. See Figure 19 & 16 toward
end of manual for a description of how the
AquaSmart’s differentials work. Consult the manual of
the control being replaced for information regarding its
differentials.
1.
2.
3.
4.
5.
Installing the Temperature Sensor
Figure 4a - Installation of Temperature Sensor in Immersion Well
This is very important for successful control operation.
Temperature Sensor
Brass Fitting
Sensor must butt against end
Copper Well Tube
Sensor connects to Beckett AquaSmart
Removing the Control to be Replaced
Figure 4b - Strain Relief
Electrical shock hazard.
Disconnect all electrical power to the appliance
circuit before replacing the control. There may be
more than one disconnect switch.
Burn and Scald Hazard
Excessive water temperatures could cause
explosion, burns, scalding, pressure relief fl ooding
and fi tting leaks.
Carefully follow the outlined procedures for temperature
sensor installation to ensure accurate water
temperature sensing and effective control operation.
Make sure the plumbing for domestic hot water has
anti-scald valve protection.
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Make sure the immersion well is clean inside, has no
leaks, is of proper length and is otherwise suitable for
receiving the new control and temperature sensor.
Replace questionable wells with new ones and use
pipe sealant to seal the threads.
Grasp the sensor lead, just behind the sensor probe
and carefully insert it into the well until it comes to rest
at the very end of the well.
The sensor is designed
with radial splines to provide a snug fi t in most
standard wells.
The thermal time constant of the sensor is 40
seconds. Consider using thermal grease if faster
response in desired.
Surface mounting may require additional lead length
to reach the control receptacle. Use the extension
cable (part no. 52120), found in the 7600RMU Remote
Mount Kit, to extend the lead by 48”.
Install the strain relief (part no. 3266201) as shown,
capturing the cable against the hex. Crimp the
strain relief opposite side of the cable. This anchors
the sensor securely inside the immersion well.
Plug the temperature sensor lead terminal into the
receptacle on the control base. See Figure 10.
Note: The sensor is not tested and approved for being
mounted to the outside of a pipe. It is for use in immersion
wells only.
1.
2.
3.
4.
5.
6.
7.
8
Installing the 2-in-1 Sensor
For proper operation, there
must be a secure electrical bond
between the green sensor wire from the sensor and
the boiler metal vessel in direct contact with the boiler
water. Failure to secure an electrical bond will result in
the AquaSmart locking out and displaying, “LOCKOUT
- LOW WATER”.
Explosion,
Burn and Scald Hazards
Excessive water temperatures could cause explosion,
burns, scalding, pressure relief fl ooding and fi tting leaks.
The 2-in-1 Sensor shall only be installed by a trained
professional.
The sensor must be installed in the proper location
for correct low water cut-off (LWCO) operation in
accordance with the Boiler Manufacturer’s
instructions.
The 2-in-1 sensor body is installed directly into the
boiler wall tapped hole in place of an immersion well.
Carefully follow the outlined procedures for temperature
sensor installation to ensure accurate water
temperature sensing and effective control operation.
Make sure the plumbing for domestic hot water has
anti-scald valve protection.
Follow all applicable safety codes, rules and guidelines
for installing an immersion well. Improper installation
can result in the Boiler overheating.
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Do not use in steam
applications. For use in
hot water boilers or water heaters only. Do
not use outside of the intended use and
specifi cations.
Leak, Burn, and Scald
Hazards
Incompatible thread sealants could severely damage
the sensor threads.
Only use Tefl on
®
Tape or Rectorseal
®
No. 5
®
(soft-set).
DO NOT use any anaerobic fast-setting sealants
such as, but not limited to, Loctite
®
, Leak Lock
®
,
Permatex
®
, or Gasoila
®
.
Call RWB Technical Services at 1(800)645-2876 to
confi rm, if unsure.
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Part No.
A
Lead Length
B
Insulation Depth
C
Insertion Depth
76002N1S01
8-1/4” 1-1/2” 1-5/8”
76002N1S02
6-1/4” 3-1/2” 1-5/8”
76002N1S05
5” 4-3/4” 1-5/8”
76002N1S06
8-1/4” 1-1/2” 7/8”
Figure 5 - Overall Dimensions & Specifi cations
A
B
C
1-1/8” hex
Specifi cations
Storage Temperature Range
-40° to 250°F
Operating Temperature Range
-32° to 250°F
Maximum Pressure
250 PSIG
Installation Torque Range (Screw-in)
185 - 200 in/lbs.
9
AquaSmart Boiler Control Manual
Test the Low Water Cut-off (LWCO) Safety Function
WARNING! Avoid touching or shorting the live
terminals during this test.
Turn electric power ON to energize AquaSmart control.
Perform the following tests to verify the LWCO function.
For AquaSmart 7600A: Remove the green sensor
lead from the ground screw. The sensor should cause
the AquaSmart display to indicate, “LOCKOUT – LOW
WATER”. If it does not, replace the sensor.
For AquaSmart 7600B:
Remove the green sensor
lead from the ground screw and remove both the B1 and
B2 (24 Vac) leads from their terminals. The sensor should
cause the AquaSmart display to indicate, “LOCKOUT –
LOW WATER”. If it does not, replace the sensor.
Attach wires and tighten terminal screws securely
when testing is complete.
•
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•
2-in-1 Installation Instructions
This is very important for successful control operation.
Remove the existing immersion well. Clean the
threads in the boiler port tapping. Follow all applicable
safety codes, rules and guidelines for removing/
installing immersion wells.
Apply pipe sealant to the 2-in-1 sensor threads and
install it securely into the port. BECKETT
RECOMMENDS ONLY TO USE TEFLON TAPE OR
RECTORSEAL NO. 5 PIPE SEALANT.
Tighten with 1-1/8” open end or box wrench. Pipe
wrenches, pliers, and adjustable wrenches will
damage/round-off the hex.
Securely install the AquaSmart control to the sensor.
Plug the 2-in-1 Sensor RJ connector (phone jack style)
into the receptacle (Item a, Figure 6) on the control.
Route the 36” green wire through the AquaSmart
bottom rectangular slot (Item c, Figure 6). Securely
install the fork connector of the 36” ground wire and
the ground wire from the 2-in-1 sensor under the
ground screw at the bottom of the control (Item b,
Figure 6).
Thoroughly clean the pipe surface and securely
tighten the pipe clamp on the water inlet pipe to the
boiler as close to the boiler as possible.
Route the 36” green ground wire to the pipe clamp
then cut to proper length, if necessary.
Strip the wire and insert the stripped end into hole on
the pipe clamp (item d, Figure 7). Tighten retaining
screw against the wire making sure that you have
good contact.
Complete control wiring and fi ll the appliance with
water to the pressure required, according to appliance
manufacturer’s instructions. Make sure all air is
purged from the system and there are no leaks. Turn
on power to the appliance and observe one call for
heat cycle with shut off at set temperature.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Figure 8 - Sensor Water Detection Method
Ground Screw
2-IN-1 SENSOR
AquaSmart
Boiler Control
Ground Wire
Pipe Clamp
Incomplete
Circuit
Water Not Present
Water Present
Complete
Circuit
Water Inlet
The AquaSmart 2-in-1 Sensor uses the “conduction”
method to detect whether water is present in the
boiler. This is done by using the water in the boiler
itself to “conduct” a signal and complete an electrical
circuit. It is necessary that the ground wire from the
sensor be bonded to the boiler wall (not the jacket -
unless the jacket is bonded to the boiler wall). When
water is not present, there is no “conduction” and the
circuit is incomplete.
For the AquaSmart we recommend that a grounding
pipe clamp be mounted to the water inlet pipe, and
that a ground wire be bonded from the pipe clamp to
the green terminal inside the AquaSmart control. The
2-in-1 sensor green “ground wire” shall also be
bonded to the green terminal in the AquaSmart
control.
Figure 6 - Sensor lead & ground screw connections
a
b
c
Figure 7 - Ground Clamp and Grounding Wire
d
10
Immersion Well or 2-in-1 Sensor
Mount the control by aligning the 7/8” diameter hole
(found on back) around the mating feature of the
immersion well or 2-in-1 sensor and press into
place. Position the control upright and tighten down
the #10 screw located on the left side of the control.
Tighten so that control is securely in place (Figure 9).
Plug the temperature sensor lead terminal into the
receptacle on the control base. See Figure 10.
Appliance Surface
Use the AquaSmart mounting template to locate the
mounting holes in a desired location on mounting
surface. The template can be found in the back of
this manual.
Use (3) #8 x 3/4” self drilling screws (.110 hole
diameter if pre-drilling) included in the installation
kit. Run screws into mounting surface, leaving a
1/4” space between bottom of screw head and
mounting surface.
Open the cover of the AquaSmart control to expose
key hole locations in plastic case. Align key holes
over mounting screws and secure in place.
Plug the temperature sensor lead terminal into the
receptacle on the control base. See Figure 10.
If necessary, use the 48” cable extension to connect
sensor to control base. Refer back to Figure 3.
1.
2.
1.
2.
3.
4.
5.
Installing the AquaSmart Control
(Refer back to Figure 3 for appropriate mounting method)
.
Figure 9 - Mounting Clamp and Screw for Immersion Well
For clarity, the printed circuit board is not shown.
Figure 10 - Temperature Sensor Lead/Receptacle
Wiring
Electrical Shock, Fire,
Explosion and Burn Hazards
This control must be installed, adjusted and put
into operation only by a trained, licensed, qualifi ed
professional or service agency in accordance with
the latest revision of the National Electric Code ANSI/
NFPA 70 (Canada CSA C22.1) state, local codes and
authorities having jurisdiction.
Follow the appliance manufacturer’s wiring diagrams
and note all safety controls.
Typical safety controls include high temperature or
pressure limits, low water cutoffs, anti-scald valves,
pressure relief valves and water feed valves.
Verify all limits and safety controls are installed and
functioning correctly, as specifi ed by the appliance
manufacturer, applicable safety standards, codes
and all authorities having jurisdiction.
Provide ground wiring to the appliance, burner and
controls.
y
y
y
y
Electrical Shock Hazard.
Can Cause Severe Injury,
Death, or Equipment Damage.
Disconnect power before wiring to prevent electrical
shock or equipment damage.
All wiring must comply with local electrical codes and
ordinances. The limits given in the specifi cations
section must not be exceeded when applying this
control. Terminals on the AquaSmart are approved for
copper wire only.
Refer to the label on the inside of the AquaSmart door or
to Technical Specifi cations in this manual for Electrical
ratings and maximum load information. Use manufacturer
instructions when wiring controlled equipment or refer to
typical hookups in Figure 12 through Figure 17.
More than one service switch may be needed to
disconnect all power to the AquaSmart. The optional
power disconnect switch interrupts power to the
AquaSmart control. Depending on system wiring, some
terminals and connections (most notably ZR and the input
to the optional power disconnect switch) may still be live.
y
y
y
11
AquaSmart Boiler Control Manual
Explosion Hazard. Can
Cause Severe Injury, Death
or Property Damage.
Use this product only in systems with a pressure relief
valve.
Wiring the AquaSmart Control
Consult the appliance wiring diagrams to check the
manufacturer’s specifi cations.
Refer to Figure 12 through Figure 17 for some
typical wiring diagrams.
Verify the wires are still labeled correctly and make
connections to the appropriate terminals on the
control wiring terminal strip.
Provide disconnect means and overload protection
as required on power supply.
Connect control conduit bracket to earth ground
using the supplied grounding screw.
B1 terminal is a 1/4 in. tab terminal (quick connect).
○
○
○
○
○
○
Figure 11 - TR, B2, & Vent Damper Connections
Water Flow Symbols Key (Figures 12 through 17)
Z
- Air Vent
- Air Separator
- Expansion Tank
- Isolation Valve
- Pressure Regulator
- Zone Valve
- Check Valve
- Circulator
Some Thermostats Are
Polarity Sensitive
Reversed polarity could cause erratic cycling of the
boiler control.
Connect the red thermostat wire (from the RH or R
terminal of the thermostat) to the T
R
terminal on the
control.
Connect the white thermostat wire (from the W
terminal of the thermostat) to the TW terminal on the
control.
y
y
7600B only: TERMINALS TR (Z or
hot) and B2 (TV or ground) offer a
24-volt supply for operating other 24 VAC equipment on
the boiler. IMPORTANT: TO PREVENT DAMAGE TO
THE CONTROL, DO NOT OVERLOAD THE
TRANSFORMER. The AquaSmart is equipped with a
30VA transformer. Make sure that the total load,
including the burner circuit and TR & B2 connections do
not exceed 30VA.
See Figure 11.
How to calculate VA - Add all AMP ratings of 24VAC
components in this circuit and multiply sum by 24 volts.
(Example: .4 + .4 + .2 + .2 = 1.2A x 24V = 28.8 VA)
When powering multiple circulators
from the C1 and C2 terminals, take
extra care not to exceed the output’s reading. If the sum
of the full load amps of all the circulators exceeds the
output’s rating, use the C1 and C2 terminals to power the
coil of a multiple-pole contactor; the contacts of which can
be wired to switch L1 to each circulator.
Observe proper polarity when wiring
L1 and L2. If polarity is reversed, a
call for heat on the ZR input may not be recognized.
TR
B2
To wire a vent damper to the 7600B,
fi rst remove jumper plug from 6-
position receptacle and then connect 6-pin connector of
the vent damper to the receptacle. See Figure 11. Once
the 7600B is operated with a vent damper, it will not
function without one (even if the jumper plug is replaced).
6-Position Vent
Damper Receptacle
12
SK10030
P1
COLD
WATER
INLET
EXPANSION
TANK
HEATING
ZONE
AIR
SEPARATOR
AIR
VENT
Figure 12 - 7600A/B single-zone connections
with or without a tankless coil
Water Flow:
Control Wiring:
1. Set “DHWP OFF” (default, see programming section for instructions)
2. Set “C1 on TT” (default, see programming section for instructions)
LOW VOLTAGE
THERMOSTAT
L2 L1 C1 C2 ZC ZR B1 B2
P1
CIRCULATOR
120 VAC
120 VAC
NEUTRAL WHITE
HOT
FIELD/MFR.
SUPPLIED
SERVICE
SWITCH
BLACK
7600A:
120 VAC BURNER OR
GAS IGNITION SYSTEM
7600B:
24 VAC GAS
IGNITION SYSTEM
TW
TR
WHITE
RED
BLACK
WHITE
SK10019
13
AquaSmart Boiler Control Manual
Figure 13 - 7600A/B multi-zone connections
with or without a tankless coil
Water Flow:
Control Wiring (Option 1): Circulator-On and -Off Delays on Zone 1 ONLY
1. Set “DHWP OFF” (default, see programming section for instructions)
2. Set “C1 on TT” (default, see programming section for instructions)
3. Circulator-on and -off delays will only affect zone 1
CONTINUED ON NEXT PAGE ►
L2 L1 C1 C2 ZC ZR B1 B2
TR
TW
SK10020
6
5
4
3
2/N
1/H
T
T
ZONE
RELAY
ZONE
2
LOW VOLTAGE
THERMOSTAT
NEUTRAL
HOT
120 VAC
BLACK
WHITE
ZONE
1
LOW VOLTAGE
THERMOSTAT
P1
CIRCULATOR
120 VAC
P2
WHITE
RED
7600A:
120 VAC BURNER OR
GAS IGNITION SYSTEM
7600B:
24 VAC GAS
IGNITION SYSTEM
FIELD/MFR.
SUPPLIED
SERVICE
SWITCH
CIRCULATOR
120 VAC
6
5
4
3
2/N
1/H
T
T
ZONE
RELAY
ZONE
3*
LOW VOLTAGE
THERMOSTAT
P3*
CIRCULATOR
120 VAC
SK10031
P1
COLD
WATER
INLET
EXPANSION
TANK
HEATING
ZONE
1
AIR
SEPARATOR
AIR
VENT
HEATING
ZONE
2
P2
P3*
HEATING
ZONE
3*
* Additional zones can be added by duplicating
the plumbing and wiring of zone 3.
14
TR
TW
SK10032
6
5
4
3
2/N
1/H
T
T
ZONE
RELAY
ZONE
1
LOW VOLTAGE
THERMOSTAT
LOW VOLTAGE
THERMOSTAT
ZONE
2
ZONE
RELAY
T
T
1/H
2/N
3
4
NEUTRAL
HOT
120 VAC
BLACK
WHITE
P1
CIRCULATOR
120 VAC
P3*
CIRCULATOR
120 VAC
6
5
4
3
2/N
1/H
T
T
ZONE
RELAY
ZONE
3*
LOW VOLTAGE
THERMOSTAT
L2 L1 C1 C2 ZC ZR B1 B2
7600A:
120 VAC BURNER OR
GAS IGNITION SYSTEM
7600B:
24 VAC GAS
IGNITION SYSTEM
FIELD/MFR.
SUPPLIED
SERVICE
SWITCH
P2
CIRCULATOR
120 VAC
6
5
Figure 13 (continued) - 7600A/B multi-zone connections
with or without a tankless coil
Control Wiring (Option 2): Circulator-On Delay on All Zones
1. Set “DHWP OFF” (default, see programming section for instructions)
2. Set “C1 on ZR” (see programming section for instructions)
3. Circulator-on delay will affect all zones. Circulator-off delay will have no effect.
◄ CONTINUED FROM PREVIOUS PAGE
* Additional zones can be added by duplicating
the plumbing and wiring of zone 3.
15
AquaSmart Boiler Control Manual
Figure 14 - 7600A/B alternate multi-zone connections
with or without a tankless coil
Water Flow:
Control Wiring (Option 1): 7600B only
1. Set “DHWP OFF” (default, see programming section for instructions)
2. Set “C1 on TT” (default, see programming section for instructions)
3. Circulator-on delay will affect all zones. Circulator-off delay will have no effect.
4. Up to two 24 VAC zone valves can be powered with the 7600B. Add an additional transformer as shown
for every two or less valves over the original two.
5. Ensure there are no jumpers between the terminals of the zone valves.
SK10033
EXPANSION
TANK
HEATING
ZONE
1
AIR
VENT
HEATING
ZONE
2
HEATING
ZONE
3*
ZZZ
ZONE 1
24 VAC
ZONE
VALVE
ZONE 2
24 VAC
ZONE
VALVE
ZONE 3*
24 VAC
ZONE
VALVE
AIR
SEPARATOR
GENERAL
CIRCULATOR
COLD
WATER
INLET
TR
TW
24 VAC GAS
IGNITION SYSTEM
T
Z
TV
SK10021
L2 L1 C1 C2 ZC ZR B1 B2
NEUTRAL
HOT
120 VAC
BLACK
WHITE
CIRCULATOR
120 VAC
GENERAL
CIRCULATOR
Y
TR TH
RR
Y
40 VA
TRANSFORMER
ZONE 1
LOW VOLTAGE
THERMOSTAT
ZONE 1
24 VAC
ZON E VALV E
ZONE 2
LOW VOLTAGE
THERMOSTAT
ZONE 3*
LOW VOLTA GE
THERMOSTAT
Taco
550
ZONE 2
24 VAC
ZON E VALV E
ZONE 3*
24 VAC
ZON E VALV E
Honeywell
V8043E, V8044E
Honeywell
V8043F
MTR
MTR
TH/
TR
32
1
MTR
FIELD/MFR.
SUPPLIED
SERVICE
SWITCH
CONTINUED ON NEXT PAGE ►
* Additional zones can be added by duplicating the
plumbing and wiring of zone 3, adding additional
transformers as needed.
16
Figure 14 (continued) - 7600A/B alternate multi-zone connections
with or without a tankless coil
Control Wiring (Option 2): 7600A only
1. Set “DHWP OFF” (default, see programming section for instructions)
2. Set “C1 on TT” (default, see programming section for instructions)
3. Circulator-on delay will affect all zones. Circulator-off delay will have no effect.
4. 24 VAC zone valves cannot be powered directly with the 7600A. Add an additional transformer for every two
or less valves.
5. Ensure there are no jumpers between the terminals of the zone valves.
◄ CONTINUED FROM PREVIOUS PAGE
TR
TW
120 VAC
BURNER OR
GAS IGNITION
SYSTEM
SK10046
L2 L1 C1 C2 ZC ZR B1 B2
NEUTRAL
HOT
120 VAC
BLACK
WHITE
CIRCULATOR
120 VAC
GENERAL
CIRCULATOR
Y
TR TH
RR
Y
40 VA
TRANSFORMER
ZONE 1
LOW VOLTAGE
THERMOSTAT
ZONE 1
24 VAC
ZONE VALVE
ZONE 2
LOW VOLTAGE
THERMOSTAT
ZONE 3*
LOW VOLTAGE
THERMOSTAT
Taco
550
ZONE 2
24 VAC
ZONE VALVE
ZONE 3*
24 VAC
ZONE VALVE
Honeywell
V8043E, V8044E
Honeywell
V8043F
MTR
MTR
TH/
TR
32
1
MTR
FIELD/MFR.
SUPPLIED
SERVICE
SWITCH
40 VA
TRANSFORMER
* Additional zones can be added by duplicating the
plumbing and wiring of zone 3, adding additional
transformers as needed.
17
AquaSmart Boiler Control Manual
SK10034
COLD
WATER
INLET
EXPANSION
TANK
AIR
SEPARATOR
AIR
VENT
HEATING
ZONE
1
INDIRECT
DHW
DHW
ZONE
P2
P1
Figure 15 - 7600A/B single-zone connections
with Indirect Domestic Hot Water (DHW)
Water Flow:
Control Wiring:
1. Set “DHWP on ZR” (see programming section for instructions)
2. Set “C1 on TT” (default, see programming section for instructions)
3. Circulator-on and -off delay will only affect zone 1.
L2 L1 C1 C2 ZC ZR B1
B2
TR
TW
SK10023
6
5
4
3
2/N
1/H
T
T
ZONE
RELAY
NEUTRAL
HOT
120 VAC
BLACK
WHITE
ZONE
1
LOW VOLTAGE
THERMOSTAT
P1
CIRCULATOR
120 VAC
P2
CIRCULATOR
120 VAC
DHW
LIMIT
CONTROL
WHITE
RED
7600A:
120 VAC BURNER OR
GAS IGNITION SYSTEM
7600B:
24 VAC GAS
IGNITION SYSTEM
FIELD/MFR.
SUPPLIED
SERVICE
SWITCH
18
SK10035
COLD
WATER
INLET
EXPANSION
TANK
AIR
SEPARATOR
AIR
VENT
HEATING
ZONE
1
INDIRECT
DHW
DHW
ZONE
P1
P2 P3
HEATING
ZONE
2
HEATING
ZONE
3*
P4*
Figure 16 - 7600A/B multi-zone connections
with Indirect Domestic Hot Water (DHW)
Water Flow:
CONTINUED ON NEXT PAGE ►
* additional zones can be added by duplicating
the plumbing and wiring of zone 3.
19
AquaSmart Boiler Control Manual
Figure 16 (continued)- 7600A/B multi-zone connections
with Indirect Domestic Hot Water (DHW)
Control Wiring (Option 1): Circulator-On and -Off Delays on DHW Zone Only
1. Set “DHWP on TT” (see programming section for instructions)
2. Set “C1 on TT” (default, see programming section for instructions)
3. Circulator-on and -off delays will only affect DHW zone.
7600A:
120 VAC BURNER OR
GAS IGNITION SYSTEM
7600B:
24 VAC GAS
IGNITION SYSTEM
L2 L1 C1 C2 ZC ZR B1 B2
TR
TW
SK10022
6
5
4
3
2/N
1/H
T
T
ZONE
RELAY
ZONE
1
LOW VOLTAGE
THERMOSTAT
LOW VOLTAGE
THERMOSTAT
ZONE
2
ZONE
RELAY
T
T
1/H
2/N
3
4
5
6
NEUTRAL
HOT
120 VAC
BLACK
WHITE
P1
CIRCULATOR
120 VAC
P2
CIRCULATOR
120 VAC
CIRCULATOR
120 VAC
P3
P4*
CIRCULATOR
120 VAC
4
3
2/N
1/H
T
T
ZONE
RELAY
ZONE
3*
LOW VOLTAGE
THERMOSTAT
DHW
LIMIT
CONTROL
FIELD/MFR.
SUPPLIED
SERVICE
SWITCH
5
6
◄ CONTINUED FROM PREVIOUS PAGE
CONTINUED ON NEXT PAGE ►
* Additional zones can be added by duplicating
the plumbing and wiring of zone 3.
20
L2 L1 C1 C2 ZC ZR B1 B2
TR
TW
SK10024
6
5
4
3
2/N
1/H
T
T
ZONE
RELAY
LOW VOLTAGE
THERMOSTAT
ZONE
1
ZONE
RELAY
T
T
1/H
2/N
3
4
5
6
NEUTRAL
HOT
120 VAC
BLACK
WHITE
P1
CIRCULATOR
120 VAC
P3
CIRCULATOR
120 VAC
4
3
2/N
1/H
T
T
ZONE
RELAY
ZONE
2
LOW VOLTAGE
THERMOSTAT
LOW VOLTAGE
THERMOSTAT
ZONE
3*
ZONE
RELAY
T
T
1/H
2/N
3
4
5
6
CIRCULATOR
120 VAC
P4*
CIRCULATOR
120 VAC
P2
DHW
LIMIT
CONTROL
7600A:
120 VAC BURNER
OR GAS IGNITION
SYSTEM
7600B:
24 VAC GAS
IGNITION SYSTEM
FIELD/MFR.
SUPPLIED
SERVICE
SWITCH
5
6
Figure 16 (continued) - 7600A/B multi-zone connections
with Indirect Domestic Hot Water (DHW)
◄ CONTINUED FROM PREVIOUS PAGE
Control Wiring (Option 2): Circulator-On Delay on All Zones
1. Set “DHWP OFF” (default, see programming section for instructions)
2. Set “C1 on ZR” (see programming section for instructions)
3. Circulator-on delay will affect all zones. Circulator-off delay will
have no effect.
4. DHW zone will not have priority over heating zones.
CONTINUED ON NEXT PAGE ►
* Additional zones can be added by duplicating
the plumbing and wiring of zone 3.
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Beckett 7600 User manual

Beckett
Brand
Beckett
Model
7600
Category
Water heaters & boilers
Type
User manual
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